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Process Design Engineer CheatSheet

This cheat-sheet provides key concepts for a Process Design Engineer interview, covering mass and energy balances, heat transfer, fluid mechanics, mass transfer operations, reaction engineering, process control, safety, and environmental considerations. It includes essential equations, definitions, and common interview questions related to these topics. The document serves as a quick reference for candidates preparing for technical interviews in the field.

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Nithyasaadhana S.M
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14 views2 pages

Process Design Engineer CheatSheet

This cheat-sheet provides key concepts for a Process Design Engineer interview, covering mass and energy balances, heat transfer, fluid mechanics, mass transfer operations, reaction engineering, process control, safety, and environmental considerations. It includes essential equations, definitions, and common interview questions related to these topics. The document serves as a quick reference for candidates preparing for technical interviews in the field.

Uploaded by

Nithyasaadhana S.M
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

Process Design Engineer Interview Cheat-Sheet

1. Mass & Energy Balances


• General Mass Balance: Input + Generation – Output – Consumption = Accumulation (Steady state → 0)
• Energy Balance: ∆H = ∆Q - ∆W
• Recycle, purge, bypass are common scenarios.

2. Heat Transfer & Heat Exchangers


• Q = U × A × ∆Tlm (LMTD method).
• ∆Tlm = (∆T1 - ∆T2)/ln(∆T1/∆T2).
• Types: Shell & tube, plate, condenser, reboiler.
• Fouling factor included in U value.

3. Fluid Mechanics
• Bernoulli: P + 1/2ρv² + ρgz = constant.
• Reynolds No.: Re = ρvd/µ → laminar <2000, turbulent >4000.
• Pump: Head = height fluid can be raised. NPSH must be > NPSHreq.

4. Mass Transfer Operations


• Distillation: Driving force = volatility difference.
• Reflux ↑ → purity ↑ but energy ↑.
• Absorption: Gas-liquid contact, tray/packed towers.

5. Reaction Engineering
• Rate law: r = kC■.
• Conversion (X) = fraction reacted.
• Reactors: Batch, CSTR (low conv.), PFR (high conv.).
• Design eqn: FA0 - FA = ∫ rA dV.

6. Process Control (Basics)


• P: Quick but steady-state error.
• PI: Removes error. PID: Best balance.
• Example: Level transmitter → Controller → Valve → Pump.

7. Safety & Environmental


• Relief valve: Overpressure protection.
• Flare: Burns excess gases.
• HAZOP: Identifies deviations in process.
• Factor of safety included in sizing.

8. Industry Diagrams
• PFD: Major equipment + flows (overview).
• P&ID;: Valves, instruments, safety devices (detail).

9. Common Interview Questions


• 1. Difference between PFD and P&ID;?
• 2. How would you size a heat exchanger?
• 3. Why is reflux used in distillation?
• 4. Function of a control valve?
• 5. What happens if NPSH < required?
• 6. When to use CSTR vs PFR?
• 7. How does a relief valve protect a system?

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